Method of producing a paraffin-active carbon electrode

ABSTRACT

A POROUS, LOW COST ALKALI STABLE ELECTRODE WHICH IS RESISTANT TO WETTING, HIGHLY EFFICIENT FOR THE ELECTROLYTIC REDUCTION OF OXYGEN TO PERYDROXYL ION AND FORMED BY COLD OR HOT PRESSING ACTIVATED CARBON HAVING PARAFFIN INTIMATELY ADSORBED THEREON.

July 6, 1971 D. H. GRANGAARD METHOD OF PRODUCING A PARAFFIN-ACTIVE CARBON ELECTRODE Original Filed Dec. 27, .1966

HOT MOLTEN PARAFFIN ACTIVE CARBON POWDER ADD MORE CARBON TO DRY MEX WHELE HEATBNG AND GRINDING COOL MHXTURE HOT MOLD POWDER MIXTURE COLD MOLD POWDER MIXTURE COOL AND REMOVE FROM MOLD REMOVE FROM OLD COMPLETE ELECTRODE CARBON- PARAFFIN COMPOSITION ELECTRODE 30-60% CARBON 70-40% PARAFFIN United States Patent" Olfiee 3,591,670 METHOD OF PRODUCING A PARAFFIN-ACTIVE CARBON ELECTRODE Donald H. Grangaard, Appleton, Wis., assignor to Kimberly-Clark Corporation, Neenah, Wis. Original application Dec. 27, 1966, Ser. No. 604,933, now Patent No. 3,459,652, dated Aug. 5, 1969. Divided and this application Mar. 17, 1969, Ser. No. 807,818 Int. Cl. H01m 13/04 US. Cl. 264-105 4 Claims ABSTRACT OF THE DISCLOSURE A porous, low cost alkali stable electrode which is resistant to wetting, highly efiicient for the electrolytic reduction of oxygen to perhydroxyl ion and formed by cold or hot pressing activated carbon having paraifin intimately adsorbed thereon.

This application is a division of co-pending application Ser. No. 604,933, filed Dec. 27, 1966, now US. Pat. No. 3,459,652.

BACKGROUND OF THE INVENTION (1) Field of the invention (2) Description of the prior art The production of solutions of hydrogen peroxide, and other oxygen-containing compounds, involving the use of a cathode electrode prepared by coating a graphite or suitable base material with active carbon as the catalytic component, together with a binder, is known in the art. Such electrodes are porous and under slight pressure pass gases quite readily. Also, such electrodes have been wet proofed to some degree against electrolyte wetting by impregnation with a dilute solution of parafiin in an appropriate solvent. The impregnation with the parafiin solution may be made by dipping or coating the electrode, and the coating of parafiin so obtained is said to be sulficiently thin that the active properties of the carbon are not influenced.

I have found, however, that electrodes produced as above described are lacking in significant utility because:

(a) Such electrodes are relatively expensive to prepare;

(b) Such electrodes have a relatively short life due to the thinness of the active carbon layer since it is difiicult to apply a layer of carbon of sufficient thickness to provide an electrode of relatively long life, and still maintain the required porosity;

(c) It is almost impossible to obtain good adhesion between the graphite base and the active carbon layer without, in turn, destroying the porosity, since maintaining the high degree of porosity necessary requires, in turn, the use of relatively low amounts of binder;

(d) Such electrodes wet easily in operation since it is very nearly impossible to adequately wet proof the electrode without, in turn, destroying the porosity; such electrodes thus have a relatively short life.

SUMMARY It is an object of this invention to provide a novel method of forming an electrode and which method overcomes the above noted defects.

3,591,670 Patented July 6, 1971 It is another object of this invention to provide a novel process for the production of an electrode and which process is characterized particularly by the provision of a powder mixture capable of being formed by either hot or cold molding procedures.

It is another object of this invention to provide a novel method of manufacturing an electrode in which powder of fine mesh is mixed with paraflin and melted under heat and pressure.

Briefly, I have found that finely divided activated carbon can be mixed with relatively large amounts of paraffin (in the molten state) and then subsequently formed into a porous electrode by a hot or cold pressing operation. Such an electrode is handleable, porous to the passage of gases, non-wetting to electrolytes, and is highly efficient for the production of peroxides, in particular an alkaline solution of hydrogen peroxide. Further, such electrodes do not require additional materials, the paraffin acting both as the wet proofing agent and as the binder. Additionally, the fact that such electrodes may be cold pressed means that they can be molded into a suitable casing which may or may not be an actual part of the cell cathode compartment. The ability to be able to mold the electrodes in this manner greatly facilitates the ease of handling of the electrodes as well as greatly simplifying the assembly of the electrolytic cells.

In the practice of my process it appears to be important that the carbon be mixed with the paraflin while the paraffin is in the molten state, and the mixing continued for such a time and to such an extent that the mixture, even though it may be hot (T=100 to 150 C.) is in the form of a dry powder. The carbon particles introduced to the hot paraffin appear to adsorb the paraflin to such an extent that a distinct thickening action occurs which, upon the further addition of the carbon, results in a mixture which is dry and powdery in appearance.

The mixture is substantially uniform and no paraflin is visible to the unaided eye after the simple mixing operation. In general, the mixture consists largely of many fine particles. At times, however, a few relatively large, but soft, agglomerates are formed which require breakdown before use. For this reason I prefer to carry out the complete process of mixing and grinding in a heated ball mill, heated sigma blade type kneader, or the like, until a lump-free, free-flowing powder is obtained. The time of milling or grinding is relatively short as the mix pulverizes extremely readily.

The fine powder (mesh, usually about to constituted by a mixture of active carbon and paraffin, I have found, can be pressed readily either hot or cold into flat plates, upon subjecting an evenly distributed layer of the paraifin-carbon mixture to pressures of the order of 250 to 1000 p.s.i. The evenly distributed layer is conventionally attained by placing a fixed weight of the mixture into a cavity type mold and striking the mixture surface with a smoothing bar until the mold is evenly and uniformly filled. Alternately, an extrusion type molding procedure may be used. In either event, the pressure should be sufficient to cause adhesion of the mass so that the binding action of the paraffin will be evident. Such contributes to strength in the ultimate product.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be more fully understood by reference to the following detailed description and accompanying drawings wherein:

FIG. 1 is a flow sheet illustrating a preferred procedure in the practice of the invention; and

FIG. 2 is a view of an electrode with appropriate legends.

3 DESCRIPTION OF THE PREFERRED EMBODIMENTS In a preferred embodiment of the process (FIG. 1) of invention, the proportion of active carbon to paraflin by weight is about 1: 1. The carbon by volume then considerably exceeds that of the paraffin. The specification of the mesh of the carbon is 50 to 75% through 325 mesh with 90-99% through 100 mesh. The hot molten parafiin (T=100 to 150 C.) under such circumstances becomes a generally heavy gel-like mass as active carbon (in the powder form) addition to the paraffin proceeds; the parafiin is adsorbed by the carbon and finally a dry powdering of the mass of the components takes place even though the mass is hot (T=ll50 C.). In this preferred practice a portion of the carbon is added and mixed with the molten paraflin to dryness; the remainder of the carbon is then added with heating and mixing. The mix commonly appears dry to the eye when about /3 to /2 of the carbon has been added in a 1:1 by weight mix. Ball milling, kneading, or the like, of the complete mass for about -15 minutes results in a powder of a mesh of 80 to 100. In some instances, as the mass cools, slight lumping of the carbon-paraffin mixture occurs. The lumps which form, however, are relatively soft and are easily broken up by means of a brush type sifter or the like. By mesh I mean capable of passing readily through an 80 mesh screen but difficultly to pass through a 100 mesh screen when screened under dry conditions. Actually, the material appears to be of even finer mesh but, due apparently to the parafiin coating on the carbon particles, difficulty is experienced when trying to screen the material when using smaller meshes. This material, when pressed in a mold at a temperature of about 300-350 F., for example, will form an integral, though extremely weak, (structurally) unit. To remove the unit from the mold, it is necessary to cool the mold and electrode, a step which increases the electrode strength for handling.

The characteristics of the mix are such that the electrode may also be cold molded. Although somewhat higher molding pressures are required, the saving in time through not having to cool the mold more than compensates for the increased pressure required. Actually, the cold molding operation can be carried out in much the same manner as preforms are made for commercial thermosetting molding operations.

The electrodes so formed are conveniently made in planar form (FIG. 2) and may be employed in stacked relation in the electrolyzing cell apparatus. If desired, the electrode may, however, have a cylindrical configuration. The surface of the active carbon appears to be largely unaffected by the inclusion of the paraffin, as the electrode produces very nearly the theoretical amount of peroxide as defined by Faradays laws. Further, air or oxygen readily passes through such an electrode, even though the thickness is of the order of 0.125" to 0.250".

For greater structural strength the electrode may be backed with other more rigid materials. Such preferably are electrically conductive and of a mesh-like structure. Further, the electrode may be molded into a suitable casing, said casing may or may not be a part of the actual cathode compartment.

In general, I prefer at least 50% of the electrode by weight to be active carbon. However, if desired, the electrode may consist of about to about 60% carbon, or about 70 to by weight of paraffin without greatly effecting the performance of the electrode. The actual ratio of carbon to paraflin used is dependent to a considerable extent upon the surface area of the carbon. The larger the surface area of the carbon, the greater the amount of parafiin which may be used. In instances where the ratio of paraffin to carbon is high, exceptional nonwetting characteristics are noted, whereas in instances where the ratio of paraffin to carbon has been lower, the electrode may for a time exhibit better performance but wets up more readily.

The carbons which I have found most useful have the following characteristics:

Surface area500-1000 m. /gm. Fineness:

-99% through mesh 70-90% through 200 mesh 5075% through 325 mesh Pore volume (cc./gm.)0.6l.1 Densitylbs. cu. ft.9l8 Iodine value9096 The parafiins most suitably employed in the practice of the invention have the following characteristics:

Tensile strength, p.s.i.-Tinius Olsen 20#/sec.260300 min.

Oil content ASTM percent0.50.3 max.

Melting point, F. AMP-l50130 Successful results have also been obtained with substantially harder paraffins wherein the softening points have been as high as F. Paraffins modified with polyethylene have also given satisfactory results. Normally the addition of added materials is not desirable unless improved strength qualities are desired.

By parafiin I mean the wax-like alkali stable substances which are produced in the petroleum industry by chilling the lubricating oil fraction when refining paraffin-base petroleum. Chemically, the material consists essentially of alkanes in the C C range.

Characteristics which particularly distinguish the electrodes of the invention include:

(1) Low cost.

(2) Easy fabrication.

(3) High performance.

(4) Long life.

(5 Capable of recovery and refabrication.

(6) Not necessary to add a special wet proofing agent.

Electrodes prepared as described above have been operated under the following conditions: the electrode forms the cathode of a cell having an anode of nickel wire mesh and the electrolyte is a 2% solution of NaOH. A diaphragm of asbestos between the anode and cathode separates the cell into an anolyte and a catholyte compartment and the same alkali solution is directed successively through the two compartments. About 2 volts are imposed between the anode and cathode to provide a current flow of about 1.5 to 3.0 amps. Operation is at room tempertaure (70 F.). Air or oxygen is directed under light pressure through the cathode and the reaction takes place in known manner.

The useful life of the electrode having equal quantities by weight of paraffin and active carbon and serving as a cathode has been found to be greater than 1000 hours, even though operated on an intermittent basis without drying between cycles. In this period of 1000 hours in actual practice the electrode was dried out after about each 100 hours of operation simply by passing dry air through the electrode. During this 1000 hours an electrode of 28 sq. in. in area formed about 800 grams of peroxide at an average current efficiency of about 2 kWh/lb. peroxide. It is to be noted that these figures apply to an intermittent and therefore very severe type of operation. The electrodes of the invention operate for much longer than 100 hours without re-drying when operated continuously. I consider it to be an extremely important feature of my new electrodes that they may be successfully dried out and re-used with practically their original efficiency. Commonly as a guide I prefer to subject electrodes to re-drying when the efficiency has dropped 10% as determined by the yield and/ or efficiency.

It has also been found that such electrodes often after they have appeared to lose their activity can be reactivated by a simple drying operation which consists essentially of simply passing a stream of dry air through and/ or over the electrode. In commercial practice, this drying operation may be carried out without disassembling the cell.

In instances where an alkaline solution of hydrogen peroxide is the desired end product, electrode cost is an extremely important factor. The cost of the electrode of this invention is low and particularly so in terms of the quantity of peroxide produced per foot square of electrode surface over the operating life of the electrode.

The term consisting essentially of is used herein in the definition of the components to indicate those components whose presence is essential and, as used, it is intended to exclude the presence of other materials in such amounts as to interfere substantially with the properties and characteristics possessed by the composition set forth but to permit the presence of other materials in such amounts as not substantially to affect said properties and characteristics adversely.

As many apparently widely different embodiments of this invention may be made without departing from the spirit and scope thereof, it is to be understood that I do not limit myself to the specific embodiments thereof except as defined in the appended claims.

I claim:

1. The process of manufacturing an electrode which is highly satisfactory for use as a cathode in the electrochemical production of peroxide, which is porous to gases but resistant to wetting by aqueous alkaline solutions, said process comprising heating parafiin wax to a molten condition, adding to the molten wax with mixing action finely divided active carbon, having a surface area of SOD-1,000 square meters per gram, until essentially a dry mix is obtained, then, while the mixture is still hot, adding and blending in sufficient of said active carbon such that the dry mix consists of between about and parts by weight of finely divided active carbon and to 40 parts by weight of paraffin, and subjecting a predetermined volume of the fine powder dry mixture to a pressure molding device to press the dry powder into a porous electrically conductive body.

2. The process according to claim 1 wherein the volume of powder is subjected to a pressure of between about 250 to 1000 p.s.i. for a time suflicient to form the fine powder into the porous electrically conductive body.

3. The process according to claim 2 wherein the volume of powder is subjected to a temperature of between about 300-350 F. during the application of the pressure, and the body is cooled before removing it from the molding device.

4. The process according to claim 1 wherein the finely divided active carbon has a mesh size of between about and 325, and the fine powder dry mixture has a particle size which is greater than that of the carbon and less than about 80 mesh.

References Cited UNITED STATES PATENTS 1,899,064 2/1933 Storey et a1 264--- 3,084,394 4/1963 Bickerdike et al 264-105 3,100,136 8/1963 DAscoli et al. 264105 3,252,839 5/1966 Langer et a1 2042 94 ROBERT F. WHITE, Primary Examiner G. AUVILLE, Assistant Examiner US 01. X.R.

136122; ze a- 330 

